Internal Diameter Atmospheric-Plasma-Sprayed High-Performance YSZ-Based Thermal Barrier Coatings
Source abstract
Abstract
Thermal barrier coatings (TBCs) play a crucial role in enhancing the operating temperature of key equipment. However, when TBCs are sprayed on the internal surface of these components, there are issues related to the imperfect internal diameter atmospheric plasma spray (ID-APS) process and the unsatisfactory performance of TBCs in internal holes. Yttria-stabilized zirconia (YSZ), YSZ + Gadolinium zirconate (GZ) and YSZ + tantalate (RETaO4) TBCs were prepared using the SM F210 ID-APS gun. The thermal shock and particle erosion resistance of the coatings were compared, and the relationship between the structure and properties was investigated. The results show that the hardness, fracture toughness and erosion resistance of the three coatings are the largest in the YSZ coating and the smallest in the GZ coating. YSZ coating also has the best thermal shock resistance. These research findings have important guiding significance for the improvement of the ID-APS process.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: High-Temperature Coating Behaviors · Nuclear Materials and Properties · Advanced materials and composites
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Key Laboratory of Pressure System and Safety, Ministry of Education, East China University of Science and Technology, Shanghai 200237, China
Shanghai Institute of Aircraft Mechanics and Control, Shanghai 200092, China
Funding
National Natural Science Foundation of China · Science Center for Gas Turbine Project · National High Technology Research and Development Program of China · Shanghai Gaofeng Project for University Academic Program Development, and Key Research and Development Projects in Anhui Province
References (58)
Show source-provided references
1. Thermal barrier coatings for gas-turbine engine applications10.1126/science.1068609 ↗
2. Ernst, P., Garcia, J., and Froelund, K. (2012, January 23–26). Technology and Contribution of SUMEBore Cylinder Liner Surface Coatings on Lubricant Oil Consumption Reduction on an EMD710 Diesel Engine. Proceedings of the ASME 2012 Internal Combustion Engine Division Fall Technical Conference, Vancouver, BC, Canada.10.1115/ICEF2012-92083 ↗
3. Application of thermal spraying in the automobile industry10.1016/j.surfcoat.2006.04.050 ↗
4. IJER editorial: The future of the internal combustion engine10.1177/1468087419877990 ↗
5. Evaluation of internal thermal barrier coatings for exhaust manifolds10.1016/j.surfcoat.2015.04.005 ↗
6. Thermal barrier coatings for internal combustion engines: A review10.1016/j.matpr.2021.10.371 ↗
7. Morawitz, U., Mehring, J., and Schramm, L. (2013). Benefits of Thermal Spray Coatings in Internal Combustion Engines, with Specific View on Friction Reduction and Thermal Management, SAE International.10.4271/2013-01-0292 ↗
8. Technical and Economical Aspects of Current Thermal Barrier Coating Systems for Gas Turbine Engines by Thermal Spray and EBPVD: A Review10.1007/s11666-007-9148-y ↗
9. Internal Diameter Coating Processes for Bond Coat (HVOF) and Thermal Barrier Coating (APS) Systems10.1007/s11666-018-0781-4 ↗
10. Steel coating application for engine block bores by Plasma Transferred Wire Arc spraying process10.1016/j.surfcoat.2014.11.018 ↗
11. Experimental Analysis on the Environment of Internal Plasma Spraying Techniques10.4028/www.scientific.net/AMM.184-185.1480 ↗
12. Optimal Design of a Novel Cold Spray Gun Nozzle at a Limited Space10.1361/105996305X59404 ↗
13. Internal diameter HVOAF thermal spray of carbon nanotubes reinforced WC-Co composite coatings10.1016/j.matdes.2021.109566 ↗
14. Advanced Robot Assisted Manufacturing and Control System for the Internal HVOF Series Coating Process of Cylinder Bores in Light Weight Engine Manufacturing
15. Effects of spraying conditions on the microstructure and properties of NiCrBSi coatings prepared by internal rotating plasma spraying10.1016/j.surfcoat.2019.06.056 ↗
16. Internal Diameter HVAF Spraying for Wear and Corrosion Applications
17. SUMEBore—The Coating Solution to Protect Cylinder Liner Surfaces10.4271/2012-01-1992 ↗
18. Influence of particle in-flight characteristics on the microstructure of atmospheric plasma sprayed yttria stabilized ZrO210.1016/S0257-8972(01)01239-7 ↗
19. Effect of the interface morphology and initial nanocrack on the fracture property of a ceramic reinforced plasma-sprayed coating10.1016/j.ceramint.2020.06.279 ↗
20. Development of a process window for a NiCoCrAlY plasma-sprayed coating
21. Effect of in-situ oxidation on the nanomechanical evolution of Fe-base coating with ceramic particles produced by internal rotating plasma spraying10.1016/j.ceramint.2019.06.241 ↗
22. Ernst, P., and Distler, B. (2012). Optimizing the Cylinder Running Surface/Piston System of Internal Combustion Engines towards Lower Emissions, SAE International.10.4271/2012-32-0092 ↗
23. Phase Stability of Thermal Barrier Coatings Made from 8 wt.% Yttria Stabilized Zirconia: A Technical Note10.1361/105996303770348474 ↗
24. Relative stability, structure, and elastic properties of several phases of pure zirconia10.1103/PhysRevB.57.741 ↗
25. Investigation of CMAS resistance of sacrificial plasma-sprayed mullite-YSZ protective layer on 8YSZ thermal barrier coating10.1016/j.corsci.2020.108764 ↗
26. Achieving high anti-sintering performance of plasma-sprayed YSZ thermal barrier coatings through pore structure design10.1016/j.surfcoat.2022.128259 ↗
27. Improve durability of plasma-splayed thermal barrier coatings by decreasing sintering-induced stiffening in ceramic coatings10.1016/j.jeurceramsoc.2019.11.074 ↗
28. Influence of pores on mechanical properties of plasma sprayed coatings: Case study of YSZ thermal barrier coatings10.1016/j.ceramint.2018.08.220 ↗
29. Thermal Shock Resistance and Bonding Strength of Novel-Structured Thermal Barrier Coatings with Different Microstructure10.1007/s11666-022-01353-9 ↗
30. Gok, M., and Goller, G. (2019). State of the Art of Gadolinium Zirconate Based Thermal Barrier Coatings: Design, Processing and Characterization, IntechOpen. [1st ed.].
31. Thermal behaviour of multilayer and functionally-graded YSZ/Gd2Zr2O7 coatings10.1016/j.ceramint.2016.11.178 ↗
32. Microstructure and thermal properties of a promising thermal barrier coating: YTaO410.1016/j.ceramint.2016.05.194 ↗
33. The tetragonal–monoclinic, ferroelastic transformation in yttrium tantalate and effect of zirconia alloying10.1016/j.actamat.2014.01.054 ↗
34. New Material Concepts for the Next Generation of Plasma-Sprayed Thermal Barrier Coatings10.1007/s11666-004-0052-4 ↗
35. Optimum pyrochlore compositions for low thermal conductivity10.1080/09500830310001646699 ↗
36. Physical properties of La2B2O7(B Zr, Sn, Hf and Ge) pyrochlore: First-principles calculations10.1016/j.jallcom.2015.12.189 ↗
37. Effects of doping Yb3+, La3+, Ti4+, Hf4+, Ce4+ cations on the mechanical properties, thermal conductivity, and electronic structures of Gd2Zr2O710.1016/j.jallcom.2018.10.240 ↗
38. Thermochemical compatibility between alumina and ZrO2–GdO3/2 thermal barrier coatings10.1016/j.actamat.2005.03.035 ↗
39. Investigation of the thermophysical properties of (Y1-xYbx)TaO4 ceramics10.1016/j.jeurceramsoc.2020.03.007 ↗
40. Mechanical and thermal properties of RETaO4 (RE = Yb, Lu, Sc) ceramics with monoclinic-prime phase10.1016/j.jmst.2020.02.051 ↗
41. Microstructure and thermal properties of RETaO4 (RE = Nd, Eu, Gd, Dy, Er, Yb, Lu) as promising thermal barrier coating materials10.1016/j.scriptamat.2016.08.019 ↗
42. Novel thermal barrier coatings based on La2Ce2O7/8YSZ double-ceramic-layer systems deposited by electron beam physical vapor deposition10.1016/j.surfcoat.2007.09.047 ↗
43. Thermal shock behavior of 8YSZ and double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings fabricated by atmospheric plasma spraying10.1016/j.ceramint.2011.12.076 ↗
44. Thermal shock performance and microstructure of advanced multilayer thermal barrier coatings with Gd2Zr2O7 topcoat10.1016/j.surfcoat.2022.128892 ↗
45. Functional performance of Gd2Zr2O7/YSZ multi-layered thermal barrier coatings deposited by suspension plasma spray10.1016/j.surfcoat.2016.12.062 ↗
46. Multilayer, Multimaterial Thermal Barrier Coating Systems: Design, Synthesis, and Performance Assessment10.1111/jace.13563 ↗
47. Yang, Z., Wang, W., Deng, S., Fang, H., Yang, T., and Wang, L. (2021). Thermal Shock Behavior and Particle Erosion Resistance of Toughened GZ Coatings Prepared by Atmospheric Plasma Spraying. Coatings, 11.10.3390/coatings11121477 ↗
48. Gadolinium Zirconate/YSZ Thermal Barrier Coatings: Plasma Spraying, Microstructure, and Thermal Cycling Behavior10.1111/jace.13204 ↗
49. New Thermal Barrier Coatings Based on Pyrochlore/YSZ Double-Layer Systems
50. Microstructure and performance of YTaO4 coating deposited by atmospheric plasma spraying on TC4 titanium alloy surface10.1016/j.surfcoat.2021.128004 ↗
51. Indention toughness testing of plasma sprayed coatings
52. Ceramic materials for thermal barrier coatings10.1016/S0955-2219(03)00129-8 ↗
53. Atmospheric plasma sprayed thick thermal barrier coatings with high segmentation crack density10.1016/j.surfcoat.2004.01.002 ↗
54. Sintering resistance of advanced plasma-sprayed thermal barrier coatings with strain-tolerant microstructures10.1016/j.jeurceramsoc.2018.07.013 ↗
55. Effect of Residual Stresses and Prediction of Possible Failure Mechanisms on Thermal Barrier Coating System by Finite Element Method10.1007/s11666-010-9512-1 ↗
56. Yang, Z., Yang, K., Wang, W., Yang, T., Fang, H., Qiang, L., Zhang, X., and Zhang, C. (2022). Investigation of Thermal Shock Behavior of Multilayer Thermal Barrier Coatings with Superior Erosion Resistance Prepared by Atmospheric Plasma Spraying. Coatings, 12.10.3390/coatings12060804 ↗
57. Relationship between particle erosion and lamellar microstructure for plasma-sprayed alumina coatings10.1016/j.wear.2005.07.006 ↗
58. Mahade, S., Venkat, A., Curry, N., Leitner, M., and Joshi, S. (2021). Erosion Performance of Atmospheric Plasma Sprayed Thermal Barrier Coatings with Diverse Porosity Levels. Coatings, 11.10.3390/coatings11010086 ↗